Futon frame and support system

ABSTRACT

A futon support comprises a frame member defining an outer boundary of a region and a bar positioned to lie in the region and including first and second ends coupled to the frame member and spaced apart longitudinally from one another. The bar further comprises first and second flat sections configured to contact a futon to support the futon in a selected position and a bight coupled to the first and second flat sections to reinforce the first and second flat sections when a load is applied to the futon.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Application Ser. No. 60/194,131, filed Apr. 3, 2000, whichis expressly incorporated by reference herein.

BACKGROUND AND SUMMARY OF THE INVENTION

[0002] The present invention relates to furniture, and particularly to aframe assembly and cushion support system for furniture. Moreparticularly, the present invention relates to a futon support forsupporting a futon.

[0003] A futon support and a futon cooperate to offer the advantages ofseveral pieces of furniture in one. For example, a futon user mayposition a futon support and an associated futon for couch or chair usefor general use, and then rearrange the futon support and futon into abed when such a use is desired. Those components may also be arranged toprovide for other positions.

[0004] Futon supports are constructed of either a metal or woodmaterial. Futon support manufacturers desire to provide sufficientmattress support for various positions while simultaneously providingcomfort for the user in each of the positions. When metal has been usedin futon support construction, cushion support has been provided by aframe including rounded tubular members welded together. Larger tubularmembers typically make up the frame of the futon support, while smallertubular members typically span between the larger members to form asupport structure for the cushion.

[0005] According to the present invention, a futon support includes aframe and a bar including a first end coupled to the frame and a secondend coupled to the frame and spaced apart longitudinally from the firstend. The bar further includes a first flat section configured to contacta futon to support the futon in a selected position, a second flatsection configured to contact the futon to support the futon in theselected position in cooperation with the first flat section, and abight coupled to the first flat section and the second flat section toreinforce the first flat section and the second flat section so that theflat section and the second flat section can support the futon when auser of the futon applies a load to the futon.

[0006] In preferred embodiments, the first flat section and the secondflat section are positioned to lie in transversely spaced-apart,co-planar relation to one another. The first flat section, the secondflat section, and the bight extend from the first end of the bar to thesecond end of the bar. The bight is serpentine-shaped and is centrallylocated in the cross-section of the bar. Each flat section extends fromeither side of the bight.

[0007] Additional features of the present invention will become apparentto those skilled in the art upon consideration of the following detaileddescription of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The detailed description particularly refers to the accompanyingfigures in which:

[0009]FIG. 1 is a perspective view of a futon assembly having a futon orcushion, a frame, and bars spanning between members of the frame toprovide support to the frame and cushion in accordance with the presentinvention;

[0010]FIG. 2 is a top view of a bar of FIG. 1 showing two flat zonesextending the length of the bar and a serpentine zone located betweenthe flat zones and similarly extending the length of the bar;

[0011]FIG. 3 is a cross sectional view of the bar of FIG. 2 showing thepreferred embodiment of the serpentine zone to have a bight and a width,and the flat zones extending from the serpentine zone by a distanceequal to a fraction of the width of the serpentine zone;

[0012]FIG. 4 is a view of the bar of FIG. 2 mounted to the tubular frameof the futon assembly of FIG. 1;

[0013]FIG. 5 is a section view of the futon assembly of FIG. 1, showingthe relative placement of the bars on the futon frame and the supportprovided by the bar's flat zones to the futon cushion;

[0014]FIG. 6 is another top view of the bar of FIG. 2;

[0015]FIG. 7 is a front elevational view of the bar of FIG. 2;

[0016]FIG. 8 is a rear elevational view of the bar of FIG. 2;

[0017]FIG. 9 is an end view of the bar of FIG. 2;

[0018]FIG. 10 is another end view of the bar of FIG. 2 and a mirrorimage of the end view of FIG. 9; and

[0019]FIG. 11 is a bottom view of the bar of FIG. 2.

DETAILED DESCRIPTION OF THE DRAWINGS

[0020] A futon assembly 10 includes a futon support 11 and a futon orcushion 12, as shown, for example, in FIG. 1. Futon support 11 isconfigured to support cushion 12 using beams or bars 14 (shown in moredetail in FIGS. 2 and 3) coupled to tubular frame members 16 in themanner shown, for example, in FIGS. 4 and 5. Each beam 14 is formed toinclude a cross-sectional serpentine zone 18, and two flat zones 20extending therefrom, as shown, for example in FIG. 3. The flat zones 20provide increased supportive surface area for the cushion 12, to provideadded comfort and support for a futon user. The serpentine zone 18provides structural support to beam 14 so that the beam does not fatigueunder the force of the weight of the user.

[0021] A futon support 11 includes a top frame 15 and a bottom frame 17coupled to top frame 15. Rails 70 of futon support 11 support bottomframe 17, as shown, for example, in FIG. 1 with respect to one of rails70. The top and bottom frames 15, 17 include tubular members 16 and bars14 that span between tubular members 16 to support the cushion 12, asshown in FIG. 1. The top frame 15 forms the back of the futon when inthe sitting position, and cooperates with a connector or linkage 19 torecline to an alternate bed position (not shown), wherein top frame 15is parallel to bottom frame 17. A preferred embodiment of bar 14 isshown in FIG. 2 as a modified flatstock steel bar having a length,width, and thickness, bar 14 being placed in futon support 11 such thateach end of the length of bar 14 is coupled to a tubular member 16.

[0022] Tubular members 16 include a first frame member 16 a and a secondframe member 16 b. First frame member 16 a defines an outer boundary ofa first region 40. Second frame member 16 b defines an outer boundary ofa second region 42. A first set 44 of bars 14 is positioned to lie infirst region 40 and is coupled to first frame member 16 a. A second set46 of bars 14 is positioned to lie second region 42 and is coupled tosecond frame member 16 b.

[0023] A cross-section of the width 21 of one of the bars 14 is shown inFIG. 3. The cross section of bar 14 is a modified flatstock thatincludes a serpentine zone 18 and a flat zone 20 extending from each endof the serpentine zone 18. The serpentine zone 18 includes a singlebight 22 that extends outwardly from the flat zone approximately onethird of an outside diameter 60 of a tubular member 16. As shown best inFIG. 3, bight 22 includes a “positively sloping” first quarter roundsection 22 a having a first radius of curvature 30, an “inverted” halfround middle section 22 b having a radius of curvature 32 that issmaller than radius of curvature 30, and a “negatively sloping” secondquarter round section 22 c having a radius of curvature 34 that isequivalent to radius of curvature 30. Bight 22 defines two points ofinflection 62. As shown in FIG. 3, flat zones 20 include a first flatsection 20 a and a second flat section 20 b positioned to lie intransversely spaced-apart, co-planar relation to first flat section 20 aso as to define a common plane 64. The components 20 a, 22 a, 22 b, 22c, and 20 b are arranged in series to give bar 14 its characteristiccross-sectional shape.

[0024] It is within the scope of this disclosure to vary shape ofsections 22 a, 22 b, 22 c and length of radii 30, 32, 34 to vary theappearance of bight 22. The presently preferred embodiment of bar 14 ismanufactured to have the following approximate dimensions: a width 21 of⅞ inch, a height 23 of {fraction (7/16)}, a thickness 25 of {fraction(1/16)}, a width of serpentine zone 18 of {fraction (11/16)}, and awidth of each flat zone 20 of {fraction (3/32)}. For example, it ispossible to form serpentine zone 18 with a plurality of bights, with adifferently proportioned bight, or with any other construction thatprovides sufficient support to the bar 14, all of which are within thescope of this disclosure.

[0025] A flat zone 20 extends from either side of serpentine zone 18, asshown by FIG. 3. The flat zone 20 has an inside surface 24 facing awayfrom the bight 22, the inside surface contacting and supporting cushion12, as shown in FIG. 5. Each flat zone 20 need only extend a fraction ofthe width of serpentine zone 18 from either side of serpentine zone 18to provide adequate comfort to a futon user. However, greater widths ofeach flat zone 20 are possible, and are within the scope of thisdisclosure.

[0026] First flat section 20 a includes a first outer edge 52 and afirst inner portion 54 coupled to first quarter round section 22 a.First inner portion 54 is positioned to lie transversely inwardly offirst outer edge 52.

[0027] Second flat section 20 b includes a second outer edge 56 and asecond inner portion 58 coupled to second quarter round section 22 c.Second inner portion 58 is positioned to lie transversely inwardly ofsecond outer edge 56.

[0028] Each bar 14 includes a first end 48 and a second end 50. Each end48, 50 of bar 14 is coupled to one of first frame member 16 a and secondframe member 16 b, preferably by welding, as shown in FIG. 4. Weldingallows for greater tolerances and therefore promotes improvedproductivity and quality in the futon. In the preferred embodiment, asshown in FIG. 5, the bars 14 are spaced apart by a distance 26 that isapproximately equal to four times the width 21 of the bar 14, or 3½inches. This spacing distance, improves the comfort and support of thefuton.

[0029] Another top view of the bar of FIG. 2 is shown in FIG. 6 andshows the flat zones extending the length of the bar and the serpentinezone disposed between the flat zones and similarly extending the lengthof the bar. FIGS. 7 and 8 show front elevational and rear elevationalviews of the bar of FIG. 2, respectively. FIGS. 9 and 10 show end viewsof the bar of FIG. 2, and FIG. 11 is a bottom view of the bar of FIG. 2.

[0030] Bars 14 cooperate with top frame 15 and bottom frame 15 toprovide a comfortable and cost effective cushion support system for afuton frame. The modified flatstock support bars provide a large surfacearea for contacting and supporting the cushion, and the bars are placedin close proximity to each other, therefore yielding an adequate cushionsupporting surface area. Thinner (than normal) cushions can be used on afuton frame made using bars 14, to promote reduced freight charges andreduced manufacturing charges without sacrificing the comfort of aperson seated on the futon.

[0031] Although the invention has been described in detail withreference to preferred embodiments, variations and modifications existwithin the scope and spirit of the invention as defined and defined inthe following claims.

What is claimed is:
 1. A futon support comprising a frame including afirst frame member defining an outer boundary of a first region and asecond frame member defining an outer boundary of a second region, aconnector coupled to the first frame member and the second frame memberso that the first frame member is movable relative to the second framemember, a first set of bars positioned to lie in the first region, and asecond set of bars positioned to lie in the second region, each of thebars of the first set of bars and the second set of bars including afirst end and a second end spaced apart longitudinally from the firstend, the first end and the second end of each of the bars of the firstset of bars being coupled to the first frame member, the first end andthe second end of each of the bars of the second set of bars beingcoupled to the second frame member, each of the bars of the first set ofbars and the second set of bars including a first flat sectionconfigured to contact a futon to support the futon in a selectedposition, a second flat section configured to contact the futon tosupport the futon in the selected position in cooperation with the firstflat section and positioned to lie in transversely spaced-apart,co-planar relation to the first flat section, and a bight that isserpentine-shaped and coupled to the first flat section and the secondflat section to reinforce the first flat section and the second flatsection so that the first flat section and the second flat section cansupport the futon when a user of the futon applies a load to the futon.2. The futon support of claim 1 , wherein the first flat section of eachbar includes a first outer edge and a first inner portion that ispositioned to lie transversely inwardly of the first outer edge, thesecond flat section of each bar includes a second outer edge and asecond inner portion that is positioned to lie transversely inwardly ofthe second outer edge, and the bight of each bar extends from therespective first inner portion to the respective second inner portion.3. The futon support of claim 1 , wherein the bight of each bar includesa positively sloping first quarter round section coupled to therespective first flat section and having a first radius of curvature. 4.The futon support of claim 3 , wherein the bight of each bar furtherincludes an inverted half round middle section having a second radius ofcurvature that is smaller than the first radius of curvature.
 5. Thefuton support of claim 4 , wherein the bight of each bar furtherincludes a negatively sloping second quarter round section coupled tothe respective second flat section and having a third radius ofcurvature that is equivalent to the first radius of curvature.
 6. Thefuton support of claim 5 , wherein the bight of each bar furtherincludes a negatively sloping second quarter round section coupled tothe respective second flat section and having a third radius ofcurvature that is equivalent to the first radius of curvature.
 7. Thefuton support of claim 1 , wherein the first flat section, the secondflat section, and the bight of each bar cooperate to define a width ofthe respective bar, and adjacent bars of one of the first set of barsand the second set of bars are spaced apart about four times the widthfrom one another.
 8. A futon support comprising a frame member definingan outer boundary of a region, and a bar positioned to lie in the regionand including a first end coupled to the frame member, a second endcoupled to the frame member and spaced apart longitudinally from thefirst end, a flat zone configured to contact the futon and including afirst outer edge and a second outer edge spaced apart transversely fromthe first outer edge, and a serpentine zone coupled to the flat zone ata location spaced apart from the first outer edge and the second outeredge to reinforce the flat zone so that the flat zone can support thefuton when a user of the futon applies a load to the futon.
 9. The futonsupport of claim 8 , wherein the flat zone includes a first flat sectionand a second flat section positioned to lie in spaced-apart, co-planarrelation to one another to define a common plane.
 10. The futon supportof claim 9 , wherein the first flat section includes the first outeredge and a first inner portion positioned to lie transversely inwardlyof the first outer edge, the second flat section includes the secondouter edge and a second inner portion positioned to lie transverselyinwardly of the second outer edge, and the serpentine zone extends fromthe first inner portion to the second inner portion.
 11. The futonsupport of claim 10 , wherein the serpentine zone includes a bight thatincludes a positively sloping first quarter round section coupled to thefirst inner portion and having a first radius of curvature, an invertedhalf round middle section having a second radius of curvature that issmaller than the first radius of curvature, and a negatively slopingsecond quarter round section coupled to the second inner portion andhaving a third radius of curvature that is equivalent to the firstradius of curvature.
 12. The futon support of claim 9 , wherein theserpentine zone includes a bight that extends from the first flatsection to the second flat section and outwardly from the common planeto support the first flat section and the second flat section.
 13. Thefuton support of claim 8 , wherein the serpentine zone includes a bightthat includes a positively sloping first quarter round section coupledto the flat zone and having a first radius of curvature.
 14. The futonsupport of claim 13 , wherein the bight further includes an invertedhalf round middle section having a second radius of curvature that issmaller than the first radius of curvature.
 15. The futon support ofclaim 14 , wherein the bight further includes a negatively slopingsecond quarter round section coupled to the flat zone and having a thirdradius of curvature that is equivalent to the first radius of curvature.16. The futon support of claim 13 , wherein the bight further includes anegatively sloping second quarter round section coupled to the flat zoneand having a third radius of curvature that is equivalent to the firstradius of curvature.
 17. A futon support comprising a frame, and a barincluding a first end coupled to the frame, a second end coupled to theframe and spaced apart longitudinally from the first end, a first flatsection configured to contact a futon to support the futon in a selectedposition, a second flat section configured to contact the futon tosupport the futon in the selected position in cooperation with the firstflat section and positioned to lie in transversely spaced-apart,co-planar relation to the first flat section, and a bight coupled to thefirst flat section and the second flat section to reinforce the firstflat section and the second flat section so that the first flat sectionand the second flat section can support the futon when a user of thefuton applies a load to the futon.
 18. The futon support of claim 17 ,wherein the bight is serpentine-shaped.
 19. The futon support of claim18 , wherein the bight defines two points of inflection.
 20. The futonsupport of claim 17 , wherein the bight includes a positively slopingfirst quarter round section coupled to the first flat section and havinga first radius of curvature.
 21. The futon support of claim 20 , whereinthe bight further includes an inverted half round middle section havinga second radius of curvature that is smaller than the first radius ofcurvature.
 22. The futon support of claim 21 , wherein the bight furtherincludes a negatively sloping second quarter round section coupled tothe second flat section and having a third radius of curvature that isequivalent to the first radius of curvature.
 23. The futon support ofclaim 20 , wherein the bight further includes a negatively slopingsecond quarter round section coupled to the second flat section andhaving a third radius of curvature that is equivalent to the firstradius of curvature.
 24. The futon support of claim 17 , wherein thefirst flat section and the second flat section cooperate to define acommon plane, the frame includes a tubular member that includes adiameter, and the bight extends from the first flat section and thesecond flat section away from the common plane a distance that is aboutone-third of the diameter of the tubular member.
 25. The futon supportof claim 17 , wherein the bight extends longitudinally from the firstend to the second end.
 26. The futon support of claim 17 , wherein thefirst flat section and the second flat section extend longitudinallyfrom the first end to the second end.
 27. A futon support comprising aframe member defining an outer boundary of a region, and a barpositioned to lie in the region and coupled to the frame member, the barincluding first means for contacting a futon to support the futon in aselected position, second means for contacting the futon to support thefuton in the selected position in cooperation with the first means, andmeans for reinforcing the first means and the second means so that thefirst means and the second means can support the futon in the selectedposition when a user of the futon applies a load to the futon, the firstmeans and the second means being spaced apart transversely from oneanother, the reinforcing means being coupled to the first means and thesecond means.
 28. The futon support of claim 27 , wherein thereinforcing means is serpentine-shaped and extends from the first meansto the second means.
 29. The futon support of claim 27 , wherein thereinforcing means includes a bight that includes a positively slopingfirst quarter round section coupled to the first means and having afirst radius of curvature.
 30. The futon support of claim 29 , whereinthe bight further includes an inverted half round middle section havinga second radius of curvature that is smaller than the first radius ofcurvature.
 31. The futon support of claim 30 , wherein the bight furtherincludes a negatively sloping second quarter round section coupled tothe second means and having a third radius of curvature that isequivalent to the first radius of curvature.
 32. The futon support ofclaim 29 , wherein the bight further includes a negatively slopingsecond quarter round section coupled to the second means and having athird radius of curvature that is equivalent to the first radius ofcurvature.
 33. The futon support of claim 27 , wherein the first meansincludes a first outer edge and a first inner portion positioned to lietransversely inwardly of the first outer edge and the reinforcing meansis coupled to the first inner portion.
 34. The futon support of claim 33, wherein the second means includes a second outer edge and a secondinner portion positioned to lie transversely inwardly of the secondouter edge and the reinforcing means is coupled to the second innerportion.
 35. The futon support of claim 27 , wherein the reinforcingmeans includes a bight coupled to the first means and the second means.36. The futon support of claim 35 , wherein the bar includes a first endand a second end spaced apart longitudinally from the first end and thebight, the first means, and the second means extend from the first endto the second end.
 37. The futon support of claim 27 , wherein the firstmeans includes a first flat section and the second means includes asecond flat section positioned to lie in co-planar relation to the firstflat section.